SuzukiSavage.com - Brake lights stuck in the "on" position

DavidOfMA Senior Member Offline Getting back in gear after a long time away Posts: 336 Beverly, MA Gender:	Brake lights stuck in the "on" position 05/25/19 at 07:44:57 Finally got my bike out this year and found that the brake light is stuck in the "on" position. Activating either the front or rear brakes does not unstick it. Anyone encounter this and know how to fix it? As the stealership around here now charges $105/hour, I'd rather do it myself. 2007 S40. Thanks, David
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MidLifeRider

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Re: Brake lights stuck in the "on" position
Reply #1 - 05/25/19 at 08:15:59

Not an expert but I would first suspect the switches. You can disconnect the front brake right under the handle. If the brake light goes out there's your culprit. If not move to the rear brake switch. It's a plunger style switch. Make sure the plunger is returning when the brake is released. It may be stuck in the on position. It's located on the right hand side where the frame downtube meets the swingarm.

That's about all I can offer.

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DavidOfMA Senior Member Offline Getting back in gear after a long time away Posts: 336 Beverly, MA Gender:	Re: Brake lights stuck in the "on" position Reply #2 - 05/25/19 at 08:58:58 Thanks! I'll take a look.
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MidLifeRider YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 16 Woodbridge, Virginia Gender:	Re: Brake lights stuck in the "on" position Reply #3 - 05/25/19 at 10:33:41 Depending on how much you ride and road conditions, I can picture the rear switch getting bombarded with road spray and debris preventing it from returning to the off position. Good luck!
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batman

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Re: Brake lights stuck in the "on" posit
Reply #4 - 05/25/19 at 10:48:19

I'll bet my bottom dollar ,you need to adjust the rear brake switch , you just pull the switch upward and turn the nut upward until the brake light goes off , the only other thing would be if the rear brake pedal ( the shaft may need to be greased) is not fully returning, or the spring base is not in groove provided on the face of the brake cover plate or the shaft thru that plate that forces the shoes apart may need grease as well. All of this is just normal maintenance as described in a Clymer book.

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DavidOfMA

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Re: Brake lights stuck in the "on" posit
Reply #5 - 05/25/19 at 19:02:52

I really hate sounding like the mechanical idiot I seem to have turned into, but where exactly is the rear brake light switch, relative to either the brake end of the cable or the front brake pedal?

Looking through Chapter 3 of the Clymer manual, and then the section on brakes toward the back of the book, has so far not enlightened me, and I can't locate it based on the pic in the earlier response to my query.

Thanks,
David

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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Brake lights stuck in the "on" posit Reply #6 - 05/25/19 at 19:57:15 It's a smaller cable connected to the same pin the rear brake cable is , at the back of the pedal , you can trace it back to the switch from there.
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MidLifeRider YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 16 Woodbridge, Virginia Gender:	Re: Brake lights stuck in the "on" position Reply #7 - 05/25/19 at 20:00:09 Right side about 4" back from swingarm connection, just above swingarm.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Brake lights stuck in the "on" position Reply #8 - 05/25/19 at 22:17:07 Look for the I.B.F. spring. That's Itty Bitty Fukkin spring. Step on the brake pedal. And watch the spring get longer. But, Justin Case, you can Prove where the problem is, by disconnecting a wire from the front brake switch. Pull a wire up front Lights go off It's not the rear switch.
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DavidOfMA Senior Member Offline Getting back in gear after a long time away Posts: 336 Beverly, MA Gender:	Re: Brake lights stuck in the "on" position Reply #9 - 05/26/19 at 12:14:00 Okay, thanks. Found the switch, pushed on the brake pedal, and there's no spring movement. Busted cable or stuck switch or something else? David
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Re: Brake lights stuck in the "on" position
Reply #10 - 05/26/19 at 20:39:13

Let's back up to my first post.

Did you check the front brake light switch first? It's easier to check. If you haven't then do so and reply back with what happened.

Under the front brake lever, there is a small black switch with two wires. Disconnect them and check brake light. Do this before we move on to the rear.

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DavidOfMA

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Re: Brake lights stuck in the "on" posit
Reply #11 - 05/27/19 at 16:43:57

I disconnected the front brake switch, and the brake light was still on. Then I manually pushed the rear switch plunger in most of the way with a screwdriver, and the light went off. When I released the plunger and it went back to it's extended position, the light went back on again.

So, the problem appears to be with the operation of the rear brake light switch. What's stuck or broken, and how do I fix it?

I am figuring that the cable that operates the switch is broken, stuck, or unhinged, but as I don't have an easy way to lift the bike up to see under there, I'm not sure what I'm looking for.

Gratefully,
David

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justin_o_guy2

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Re: Brake lights stuck in the "on" position
Reply #12 - 05/27/19 at 17:36:30

When I released the plunger and it went back to it's extended position, the light went back on again.

Without studying mine, I'm gonna say
The spring could be hung lower so it doesn't pull the switch so hard
Or
Adjust the body of the switch toward the spring.
You've located the problem, so, you're on your way to winning!

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DavidOfMA

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Re: Brake lights stuck in the "on" position
Reply #13 - 05/27/19 at 17:56:21

It doesn't look to me as if either of those will solve the problem. The spring is in an almost completely compressed position when the switch is ON, and when I pushed the plunger in manually, the spring lengthens by about 1/4" before the switch goes OFF.

I'm sure the solution is obvious to someone who knows how the switch is activated/deactivated, but it's not to me.

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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Brake lights stuck in the "on" position Reply #14 - 05/27/19 at 21:53:52 Then move the nut upward lowering the body of the switch, until the spring is completely compressed, would be logical ?
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